Surgical instrument drive element, and related devices, systems, and methods

ABSTRACT

A surgical instrument includes a shaft having a proximal end and a distal end and end effector coupled to the distal end of the shaft. An electrical transmission conduit extends along the shaft from the proximal end to the distal end and is configured to deliver electrical energy to energize the end effector. A connector assembly electrically couples the electrical transmission conduit to the end effector, and the end effector is pivotably coupled to the connector assembly. In another aspect, a surgical instrument includes a pin, an electrically conductive connector including a contact portion and an attachment, the contact portion surrounding the pin. An electrical conduit is electrically coupled to the attachment of the connector. An electrically conductive jaw including an aperture is pivotable around the contact portion, and the contact portion electrically contacts the jaw at the aperture of the jaw.

This application is a divisional application of U.S. patent applicationSer. No. 14/209,043, filed on Mar. 13, 2014, which claims the benefit ofU.S. Provisional Application No. 61/803,046, filed on Mar. 18, 2013,each of which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

Aspects of the present disclosure relate to a surgical instrument for ateleoperated (robotic) surgical system. Further aspects relate to adrive element for a surgical instrument and an electrical connection fora surgical instrument.

INTRODUCTION

Some minimally invasive surgical techniques are performed remotelythrough the use of teleoperated (robotically-controlled) surgicalinstruments (which may also be referred to as tools). In teleoperatedsurgical systems, surgeons manipulate input devices at a surgeonconsole, and those inputs are passed to a patient side cart thatinterfaces with one or more teleoperated surgical instruments. Based onthe surgeon's inputs at the surgeon console, the one or moreteleoperated surgical instruments are actuated at the patient side cartto operate on the patient, thereby creating a master-slave controlrelationship between the surgeon console and the surgical instrument(s)at the patient side cart.

Teleoperated surgical systems may have multiple arms to which surgicalinstruments may be coupled. The surgical instruments include endeffectors used to perform surgical procedures. An end effector may beactuated by a drive element. Further, when the end effector isenergized, such as for a cauterization procedure, the surgicalinstrument includes an electrical connection to provide electricalenergy to the end effector. It is desirable to provide drive elementsand electrical connections with enhanced durability while alsoperforming their respective functions within the small space of asurgical instrument.

SUMMARY

Exemplary embodiments of the present disclosure may solve one or more ofthe above-mentioned problems and/or may demonstrate one or more of theabove-mentioned desirable features. Other features and/or advantages maybecome apparent from the description that follows.

In accordance with at least one exemplary embodiment, a surgicalinstrument comprises a shaft, an end effector connected to the shaft,and a push/pull drive element. The push/pull drive element comprises ahead that extends perpendicular to a push/pull direction of thepush/pull element. The head of the push/pull drive element may have endportions each having a cross-section that differs from a cross-sectionof a main portion of the head between the end portions.

In accordance with at least one exemplary embodiment, a surgicalinstrument may comprise a shaft, an end effector connected to the shaft,and a push/pull drive element. The push/pull drive element may includean engagement portion and an end portion connected to an end of theengagement portion. The engagement portion may be in contact with theend effector to actuate the end effector. The engagement portion mayhave a first width and the end portion may have a second width, whereinthe second width is greater than the first width.

In accordance with at least one exemplary embodiment, a surgicalinstrument may comprise a shaft, an end effector connected to the shaft,at least one conduit to provide energy to the end effector, and aconnector. The connector may electrically connect the at least oneconduit to the end effector. The end effector may be in sliding contactwith a portion of the connector.

Additional objects, features, and/or advantages will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the present disclosureand/or claims. At least some of these objects and advantages may berealized and attained by the elements and combinations particularlypointed out in the appended claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the claims; rather the claims should beentitled to their full breadth of scope, including equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be understood from the following detaileddescription, either alone or together with the accompanying drawings.The drawings are included to provide a further understanding of thepresent disclosure, and are incorporated in and constitute a part ofthis specification. The drawings illustrate one or more exemplaryembodiments of the present teachings and together with the descriptionserve to explain certain principles and operation.

FIG. 1 is a top view of an exemplary embodiment of a surgical instrumentincluding a force transmission mechanism.

FIG. 2 is a partial perspective view of an exemplary embodiment of asurgical instrument having an end effector.

FIG. 3 is an exploded view of the surgical instrument of FIG. 2.

FIG. 4 is a side view of the end effector of FIG. 2, along line 4-4 ofFIG. 2, the end effector being in a closed position.

FIG. 5 is a view of the end effector of FIG. 4 in an open position.

FIG. 6 is a cut-away view of an exemplary embodiment of a clevis of asurgical instrument in accordance with the present disclosure.

FIG. 7 is a cross-section view along line 7-7 of FIG. 4 but with anexemplary embodiment of a clevis also shown.

FIG. 8 is a cross-sectional view along line 8-8 of FIG. 5 but with anexemplary embodiment of a clevis also shown.

FIG. 9 is a cut-away view of an exemplary embodiment of a clevis and anend of a projection of a drive element located within a groove of theclevis.

FIG. 10 is a partial perspective view of an exemplary embodiment of apush/pull drive element.

FIG. 11 is an exploded view of the push/pull drive element of FIG. 10.

FIG. 12 is an end view of the push/pull drive element of FIG. 10.

FIG. 13 is an end view of another exemplary embodiment of a push/pulldrive element.

FIG. 14 is a partial cut-away view of an exemplary embodiment of asurgical instrument clevis and a push/pull drive element.

FIG. 15 is a partial cut-away view of an exemplary embodiment of aclevis and an end of a projection of a push/pull drive element.

FIG. 16 is a partial cut-away view of an exemplary embodiment of anon-energized surgical instrument.

FIG. 17 is a cut-away view of an exemplary embodiment of a surgicalinstrument clevis and a push/pull drive element.

FIG. 18 is a partial side cut-away view of an exemplary embodiment of asurgical instrument.

FIG. 19 is a partial side cut-away view of the surgical instrument ofFIG. 18 with a jaw removed.

FIG. 20 is a perspective view of an exemplary embodiment of a connectorassembly.

FIG. 21 is an exploded view of the connector assembly of FIG. 20.

FIG. 22 is a perspective view of an exemplary embodiment of a connectionportion of a connector assembly.

DETAILED DESCRIPTION

Exemplary embodiments discussed herein regard a surgical instrument fora teleoperated surgical system. The surgical instrument may berelatively simple and inexpensive to manufacture, while providing arobust configuration resulting in a relatively durable instrument ableto perform multiple functions within a relatively compact design.

This description and the accompanying drawings that illustrate exemplaryembodiments should not be taken as limiting. Various mechanical,compositional, structural, electrical, and operational changes may bemade without departing from the scope of this description and theinvention as claimed, including equivalents. In some instances,well-known structures and techniques have not been shown or described indetail so as not to obscure the disclosure. Like numbers in two or morefigures represent the same or similar elements. Furthermore, elementsand their associated features that are described in detail withreference to one embodiment may, whenever practical, be included inother embodiments in which they are not specifically shown or described.For example, if an element is described in detail with reference to oneembodiment and is not described with reference to a second embodiment,the element may nevertheless be claimed as included in the secondembodiment.

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing quantities, percentages, orproportions, and other numerical values used in the specification andclaims, are to be understood as being modified in all instances by theterm “about,” to the extent they are not already so modified.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the following specification and attached claims areapproximations that may vary depending upon the desired propertiessought to be obtained. At the very least, and not as an attempt to limitthe application of the doctrine of equivalents to the scope of theclaims, each numerical parameter should at least be construed in lightof the number of reported significant digits and by applying ordinaryrounding techniques.

It is noted that, as used in this specification and the appended claims,the singular forms “a,” “an,” and “the,” and any singular use of anyword, include plural referents unless expressly and unequivocallylimited to one referent. As used herein, the term “include” and itsgrammatical variants are intended to be non-limiting, such thatrecitation of items in a list is not to the exclusion of other likeitems that can be substituted or added to the listed items.

This description's terminology is not intended to limit the presentdisclosure or claims. For example, spatially relative terms—such as“beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, andthe like—may be used to describe one element's or feature's relationshipto another element or feature as illustrated in the figures. Thesespatially relative terms are intended to encompass different positions(i.e., locations) and orientations (i.e., rotational placements) of adevice in use or operation in addition to the position and orientationshown in the figures. For example, if a device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be “above” or “over” the other elements or features.Thus, the exemplary term “below” can encompass both positions andorientations of above and below. A device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

Teleoperated surgery generally involves the use of a manipulator thathas multiple manipulator arms. One or more of the manipulator arms oftensupport a surgical instrument. One or more of the manipulator arms maybe used to support a surgical image capture device, such as an endoscope(which may be any of a variety of structures such as a laparoscope, anarthroscope, a hysteroscope, or the like), or, optionally, some otherimaging modality (such as ultrasound, fluoroscopy, magnetic resonanceimaging, or the like). Typically, the manipulator arms will support atleast two surgical tools corresponding to the two hands of a surgeon andone image capture device. Such teleoperated surgical systems aredescribed in U.S. Pat. No. 8,545,515 entitled “Curved Cannula SurgicalSystem,” issued on Oct. 1, 2013, which is hereby incorporated byreference in its entirety.

Turning to FIG. 1, a side view of an exemplary embodiment of a surgicalinstrument 100 for a teleoperated surgical system is shown. Surgicalinstrument 100 may include a force transmission mechanism 110, a shaft122 connected to force transmission mechanism 110 at a proximal end 123of shaft 122, and an end effector 120 connected to a distal end 124 ofshaft 122. Shaft 122 may be flexible. According to an exemplaryembodiment, shaft 122 may have a diameter ranging from about 3 mm toabout 15 mm. According to another exemplary embodiment, the diameter ofshaft 122 may range, for example, from about 5 mm to about 8 mm.Surgical instrument 100 may include one or more members to translateforce between force transmission mechanism 110 and end effector 120. Forinstance, one or more drive element(s) 126 may connect forcetransmission mechanism 110 to end effector 120 to provide actuationforces to end effector 120, such as by extending through an interior ofshaft 122. By utilizing drive element(s) 126, force transmissionmechanism 110 may actuate end effector 120 to, for example, control awrist mechanism (not shown in FIG. 1) of instrument 100 and/or tocontrol a jaw of end effector 120 (or other moveable part). Further,because end effector 120 may be fixed to shaft 122, force translatedfrom force translation mechanism 110 to end effector 120 may in turn betranslated to shaft 122, such as when force translation mechanism 110actuates end effector 120 in a rolling motion. Drive element(s) 126 maybe in the form of tension elements, such as when force transmissionmechanism 110 is a pull-pull mechanism, or one or more drive elementrods or push rods, such as when force transmission mechanism 110 is apush-pull mechanism, as described in U.S. Pat. No. 8,545,515.

Force transmission mechanism 110 may include one or more components toengage with a patient side cart of a teleoperated surgical system totranslate a force provided by patient side cart to surgical instrument100. According to an exemplary embodiment, force transmission mechanism110 may include one or more interface disks 112, 114 that engage with amanipulator of a patient side cart, as described in U.S. Pat. No.8,545,515. Thus, interface disks 112, 114 utilize actuation forces froma manipulator to actuate instrument 100. For instance, first disk 112may be configured to provide a rolling motion to shaft 122 and provide aroll DOF for end effector 120, while second disk 114 may operate a jawmechanism of end effector 120 to open and close. The force transmissionmechanism may include other interface disks that actuate various otherfunctionalities of a surgical instrument, as those having ordinary skillin the art are familiar with.

Turning to FIG. 2, an exemplary embodiment of a surgical instrument 200for a teleoperated surgical system is shown that includes a shaft 202,clevis 204, and an end effector 206. According to an exemplaryembodiment, surgical instrument 200 may include a wrist that couples theclevis 204 to the shaft 202, or surgical instrument 200 may be anon-wristed instrument. If surgical instrument 200 lacks a wrist, endeffector 206 may be directly connected to clevis 204 and clevis 204 maybe directly connected to shaft 202. As shown in FIG. 3, which is anexploded view of the exemplary embodiment of FIG. 2, end effector 206may include a first jaw 220 and a second jaw 230. First jaw 220 mayinclude a grip portion 222, a connection aperture 224, and an actuationaperture 226. Similarly, second jaw 230 may include a grip portion 232,a connection aperture 234, and an actuation aperture 236.

According to an exemplary embodiment, connection apertures 224, 234 maybe used to connect jaws 220, 230 to clevis 304, which is in turnconnected to shaft 202. For instance, as shown in the exemplaryembodiment of FIGS. 2 and 3, a rivet or pin 208 may be inserted throughconnection apertures 224, 234 and through an aperture 205 in clevis 204to connect jaws 220, 230 to clevis 204. Pin 208 may also serve as anaxis of rotation about which jaws 220, 230 rotate when end effector 206is actuated to open and close jaws 220, 230, which will be describedbelow.

Surgical instrument 200 may include a mechanism to actuate end effector206, such as to open and close jaws 220, 230. As shown in the exemplaryembodiment of FIG. 3, surgical instrument may include a drive element210 connected to end effector 206. A proximal end (not shown) of driveelement 210 may be connected to a manipulator (not shown) of ateleoperated surgical system that provides motive force to drive element210. For instance, drive element 210 may be a push/pull drive elementrod that is pushed or pulled along direction 213 in FIG. 3 by a motiveforce provided by the manipulator to actuate end effector 206.

A distal end 215 of drive element 210 may be connected to end effector206 to translate the motive force from the manipulator to the jaws 220,230. According to an exemplary embodiment, distal end 215 of driveelement 210 may include a first projection 212 connected to jaw 220 anda second projection 214 connected to jaw 230. For instance, jaw 220 mayinclude an actuation aperture 226 that first projection 212 is insertedinto and jaw 230 may include an actuation aperture 236 that secondprojection 214 is inserted into. Actuation apertures 226, 236 may be inform of, for example, elongated slots, such as rectangular or oval slotsthat projections 212, 214 may be inserted into. Thus, as drive element210 is pushed or pulled along direction 213 in FIG. 3, projections 212,214 may slide within actuation apertures 226, 236, causing jaws 220, 230to pivot about pin 208.

Turning to FIG. 4, a side view of end effector 206 is shown along line4-4 in FIG. 2 but without clevis 204 and pin 208. In the exemplaryembodiment of FIG. 4, the jaws 220, 230 of end effector 206 are in aclosed state. Although drive element 210 is not shown in FIG. 4, secondprojection 214 is shown within actuation slot 236 of jaw 230. When driveelement 210 is pushed in direction 217 in FIG. 4, second projection 214is forced upwards. Consequently, jaws 220, 230 rotate and pivot aboutpin (not shown) located in connection aperture 234 in direction 219 inFIG. 5, causing jaws 220, 230 to separate and open.

Surgical instrument 200 may include one or more features to assist withthe movement of drive element 210 during actuation of end effector 206,such as between the closed and open states shown in the exemplaryembodiments of FIGS. 4 and 5, respectively. According to an exemplaryembodiment, clevis 204 may include one or more features to assist withthe movement of drive element 210. Turning to FIG. 6, a cut away view ofan exemplary embodiment of clevis 204 is provided. Clevis 204 includes asidewall 246 that forms an outer surface of clevis 246 and in FIG. 6 aportion of sidewall 246 has been removed to show internal features ofclevis 204. Clevis 204 may include a lumen 244 for passage of driveelement 210 through clevis 204 and an aperture 205 for a pin 208 toconnect jaws 220, 230 of an end effector 206, as discussed above inregard to the exemplary embodiment of FIG. 3. According to an exemplaryembodiment, clevis 204 may include other lumens for other components,such as, for example, conduits to provide energy to end effector 206(e.g., electrical wires) and/or additional actuation components (e.g.,an actuation element for an additional degree of freedom for surgicalinstrument or for a component, such as a knife).

To assist with the movement of drive element 210, clevis 204 may includeone or more features to interact with the projections 212, 214 of driveelement 210. For instance, clevis 204 may include a groove 240 in thesidewall 246, as shown in the exemplary embodiment of FIG. 6. Accordingto an exemplary embodiment, groove 240 may have a finite depth and abottom surface 245, as shown in FIG. 6. However, the configuration ofgroove 240 is not limited to such a geometry and groove 240 may insteadbe provided as a slot (not shown) that passes completely throughsidewall 246 of clevis 204. One or more projections 212, 214 of driveelement 210 may be configured to extend into groove 240 so that whendrive element 210 is moved to actuate end effector 206, groove 240supports a projection 212, 214. In other words, one or more projections212, 214 of drive element 210 may have a length sufficient to extendthrough jaws 220, 230 (such as through actuation apertures 226, 236) andinto groove 240 in sidewall 246.

Turning to FIG. 7, a cross-section view is shown along line 7-7 of FIG.4 is shown but with clevis 204 also provided. FIG. 8 depicts across-sectional view along line 8-8 of FIG. 5 but with clevis alsoprovided. As shown in the exemplary embodiment of FIG. 7, clevis 204 mayinclude two grooves 240; one for each projection 212, 214 of driveelement 210. In addition, grooves 240 may be opposed to one another, asshown in FIG. 7. Because projections 212, 214 of drive element 210 areplaced within grooves 240, when drive element 210 is moved to actuate anend effector 206 (e.g., by moving drive element 210 in and out of thepage of FIG. 7), grooves 240 support and/or guide the movement ofprojections 212, 214 and thus drive element 210. For instance, at leastone of sidewalls 241, 243 of groove 240 may contact projections 212, 214as drive element 210 is moved and projections 212, 214 slide back andforth within groove 240. According to an exemplary embodiment, a bottomsurface 245 of groove 240 may be in contact with projections 212, 214 tosupport projections 212, 214, either alternatively or in addition tocontact with one or more sidewalls 241, 243. Turning to FIG. 9, acut-away view of an exemplary embodiment of clevis 204 is shown, whichis similar to the view of FIG. 6, except that the end of projection 212is shown within groove 240. As shown in the exemplary embodiment of FIG.9, projection 212 may contact sidewalls 241, 243 of groove 240, such asat contact portions 248, so that projection 212 is supported by groove240. Because projections 212, 214 have a substantially circular crosssection, even at the ends of projections 212, 214 that fit withingrooves 240, contact portions 248 may be characterized by contactbetween a circle and a planar surface. For instance, contact portions248 may be a substantially tangential contact portion betweenprojections 212, 214 and sidewalls 214, 243 of groove 240. In otherwords, contact portions 248 may have a shape of line or a point. Thus,all of the stress transmitted between projections 212, 214 and sidewalls241, 243 is concentrated to relatively small areas.

When drive element 210 is moved to actuate an end effector 206 to openand close jaws 220, 230, portions of jaws 220, 230 may move apart fromone another. This is also demonstrated in FIGS. 7 and 8. In FIG. 7, jaws220, 230 are in a closed position, as shown in the exemplary embodimentof FIG. 4. In FIG. 8, jaws 220, 230 have been moved to an open positiondue to the movement of drive element 210, as shown in the exemplaryembodiment of FIG. 5. In particular, the proximal ends of jaws 220, 230may move in different directions when jaws 220, 230 move to an openposition, as shown in the exemplary embodiment of FIG. 5. This is alsodemonstrated in FIG. 8, which shows that the end of jaw 220 has moved indirection 250 relative to FIG. 7 and that the end of jaw 230 has movedin direction 252 relative to FIG. 7.

Because of the motions of jaws 220, 230 in respective directions 250,252, a torque is exerted upon drive element 210 in direction 254 shownin the exemplary embodiment of FIG. 8. Torque in direction 254 causesdrive element 210 to twist, resulting in projection 212 exerting forceagainst sidewall 243 of one groove 240 and projection 214 exerting forceagainst sidewall 241 of another groove 240. Further, due to the geometryof contact portions 248 between projections 212, 214 and sidewalls 241,243 of grooves 240, such as line or point contact, the force exertedbetween projections 212, 214 and sidewalls 241, 243 is limited to smallareas. As a result, grooves 240 may permanently deform and/or wear asprojections 212, 214 slide back and forth within grooves 240 and pressagainst sidewalls 241, 243. According to an exemplary embodiment, jaws220, 230 may move in opposite directions to directions 250, 252 shown inthe exemplary embodiment of FIG. 8 when jaws 220, 230 are actuated to aclosed position, which may result in a torque and twisting motion in adirection opposite to direction 254 in FIG. 8.

According to an exemplary embodiment, clevis 204 may be made from anon-metallic material. For instance, clevis 204 may be made of aplastic, such as, for example polyether ether ketone (PEEK), includingglass filled PEEK. When clevis 204 is made of a non-metallic material,for example, a plastic material, permanent deformation and/or wear mayoccur on the surfaces of grooves 240, such as sidewalls 241, 243. Inaddition, forces between projections 212, 214 and sidewalls 241, 241 mayeven be sufficient for projections to pop out of grooves 240 when driveelement 210 is twisted in direction 254, particularly when sidewalls241, 243 have become worn.

In view of these considerations, it may be desirable to provide asurgical instrument with enhanced durability. In particular, it may bedesirable to provide a surgical instrument with one or more features tosupport and/or guide the movement of a drive element for an end effectorthat have enhanced durability, such as by enhancing the distribution offorce between the drive element and another component of the surgicalinstrument.

Turning to FIG. 10, a perspective view of an exemplary embodiment of apush/pull drive element 300 is shown. Push/pull drive element 300 maybe, for example, a push rod, a wire, a cable, or other structure knownby one of ordinary skill in the art for use as a push/pull driveelement. For instance, push/pull drive element may be an element withsufficient columnar compressibility to transmit an axial pushing forceapplied to the push/pull drive element. Push/pull drive element 300 maybe used according to the same functions as drive element 210 describedabove for the exemplary embodiments of FIGS. 2-9. As shown in FIG. 10,push/pull drive element 300 may include a shaft 302 connected to a head304. Head 304 may include, for example, a cross shaft 309 and endportions 306, as shown in FIG. 11. Cross shaft 309 may also be referredto, for example, as a main portion of head 304. Head 304 may be formedfrom separate pieces, such as cross shaft 309 and end portions 306, asshown in the exemplary embodiment of FIGS. 10 and 11, or head 304 may beprovided with a single piece construction by providing cross shaft 309and end portions 306 as a single piece. According to an exemplaryembodiment, portions of push/pull drive element 300, such as shaft 302and cross shaft 309 and end portions 306, may be made of a metal. Forexample, portions of push/pull drive element 300 may be made of a wearresistant stainless steel alloy, such as Nitronic® 60.

According to an exemplary embodiment, push/pull drive element 300 mayinclude an insulative material 308, such as when push/pull drive element300 is used in a surgical instrument is energized, as will be discussedbelow. Insulative material 308 may be a material that minimizes arcingand electrical conductivity, such as, for example, a plastic material.As shown in the exemplary embodiment of FIG. 10, insulative material 308may be provided on at least a portion of cross shaft 309 and shaft 302.For instance, insulative material 308 may be provided on at least one ofcross shaft 309 and shaft 302 by overmolding the insulative material308.

According to an exemplary embodiment, cross shaft 309 includesengagement portions 310 that engage with portions of an end effectorwhen push/pull drive element 300 is moved to actuate the end effector.For instance, engagement portions 310 may be configured to engageactuation apertures 226, 236 of jaws 220, 230 of end effector 206, asdescribed above in the exemplary embodiments of FIGS. 2-5, to actuateend effector 206 when push/pull drive element 300 is moved. According toan exemplary embodiment, engagement portions 310 may have a circularcross-section, like projections 212, 214 of the exemplary embodiments ofFIGS. 2-8. Further, engagement portions 310 of cross shaft 309 may havea diameter 311 (see FIG. 11) substantially the same as diameter 247 ofprojections 212, 214 (see FIG. 9). However, the diameter 311 ofengagement portions 310 need not be substantially the same diameter 247of projections 212, 214, but instead may be different. For instance, thediameter 311 of engagement portions 310 may be smaller than the diameter247 of projections 212, 214, according to an exemplary embodiment.

According to an exemplary embodiment, engagement portions 310 may have anon-circular cross-section. For instance, a cross-sectional shape ofengagement portions 310 may include one or more flat surface portions(not shown). One or more flat surface portions may be provided toincrease the contact area between engagement portions 310 and actuationapertures 226, 236 of jaws 220, 230, such as to increase thedistribution of forces exerted between engagement portions 310 and jaws220, 230. According to an exemplary embodiment, actuation apertures 226,236 of jaws 220, 230 may have a different shape than the shape shown inthe exemplary embodiment of FIGS. 2 and 3. For instance, actuationapertures 226, 236 may be curved, instead of being straight as shown inFIGS. 2 and 3. For example, actuation apertures 226, 236 may be curvedso that actuation apertures 226, 236 are either convex or concave inshape relative to connection apertures 224, 234 in the exemplaryembodiment of FIG. 3.

End portions 306 of push/pull drive element 300 may be configured toenhance the distribution of forces between end portions 306 and othercomponents of a surgical instrument, such as a clevis. As shown in theexemplary embodiment of FIGS. 10 and 11, end portions 306 may be largerthan engagement portions 310 of cross shaft 309. For instance,engagement portions 310 may have a diameter or width 311, while endportions 306 may have a width 313 or 315 that is larger than the width311 of engagement portions 310. If dimensions 313, 315 of end portions306 are not equal or substantially equal, the width of end portions 306may be the larger of dimensions 313, 315, according to an exemplaryembodiment. For instance, when dimension 315 of end portion 306 islarger than dimension 313, dimension 315 is the width of end portionsand is also larger than the width 311 of engagement portions 310.According to an exemplary embodiment, a ratio of dimension 315 todiameter 311 is greater than 1. For example, a ratio of dimension 315 todiameter 311 ranges from, for example, about 1.1 to about 1.3. Accordingto an exemplary embodiment, dimension 315 may have a length of, forexample, about 0.075 inches while diameter 311 is, for example, about0.061 inches.

End portions 306 of push/pull drive element 300 may have a cross-sectionwith various shapes. As shown in the exemplary embodiments of FIGS. 10and 11, end portions 306 may have a rectangular shape. As shown in theexemplary embodiment of FIG. 12, end portions 306 may have a squareshape. According to another exemplary embodiment, an end portion 320 mayhave an oval shape, as shown in FIG. 13. The oval shape may include flatsurfaces 322, 324 and rounded ends 323, as shown in the exemplaryembodiment of FIG. 13. However, the cross-sectional shape of endportions of a push/pull drive element is not limited to the exemplaryembodiments of FIGS. 10-13 and other shapes may be utilized.

According to an exemplary embodiment, a cross-sectional shape of an endportion of a push/pull drive element includes one or more flat surfaceportions. As shown in the exemplary embodiments of FIGS. 11 and 12, endportions 306 may include flat surface portions 317, 319. Further, an endportion 320 having an oval shape or other non-rectangular or non-squareshape may have flat surface portions 322, 324, as shown in the exemplaryembodiment of FIG. 13. According to an exemplary embodiment, flatsurface portions may be opposite to one another and substantially inplanes that are parallel to the elongated direction of the groove 240 ofthe clevis, as shown in the exemplary embodiments of FIGS. 11-13.

By providing end portions 306 with a cross-section that is enlargedrelative to that of the cross shaft 309, providing end portions 306having a shape described above, and/or providing end portions 306 havingat least one flat surface portion in a plane parallel to the elongateddirection of the groove 240 of the clevis, a contact area between endportions 306 and a clevis of a surgical instrument may be increased.This in turn may enhance the distribution of forces between end portions306 and the clevis.

Turning to FIG. 14, a cut away view of a clevis 330 is provided to showinternal features of clevis 330, including groove 340 formed in asidewall 336 of clevis 330. Clevis 330 may further include an aperture335 for a pin (not shown) to connect the jaws of an end effector andgroove 340 may include sidewalls 341, 343. As shown in the exemplaryembodiment of FIG. 14, an end portion 306 of a push/pull drive element300 may be placed within groove 340 so that groove 340 supports and/orguides end portion 306 as push/pull drive element 300 moves back andforth to actuate an end effector. In particular, the one or more surfaceportions of end portion 306 may be in contact with one or more surfacesof groove 340. Turning to FIG. 15, which is side view of clevis 340 andpush/pull drive element 300, with an end portion 306 of push/pull driveelement 300 located within groove 340, surface portions 317, 319 of endportion 306 may engage one or both of sidewalls 341, 343 of groove 340via contact portions 350. According to an exemplary embodiment, surfaceportions 317, 319 may be flat. Because end portion 306 has one or moresurface portions 317, 319, contact portions 350 between end portion 306and sidewalls 341, 343 of groove 340 are not limited to point contactsor approximately tangential contacts, as discussed above in regard tothe exemplary embodiment of FIG. 9, but instead provide relatively largecontact areas over which the forces exerted between end portion 306 andgroove 340 may be distributed. As a result, the forces are notconcentrated to a small area, which may lead to permanent deformationand/or increased wear rates. Further, end portions 306 of push/pulldrive element 300 have enhanced resistance to the forces exerted whenpush/pull drive element 300 actuates an end effector and is subjected totwisting, as described above in regard to the exemplary embodiment ofFIGS. 7 and 8.

As described above with regard to the exemplary embodiments of FIGS.10-14, push/pull drive element 300 may include an insulative material308, particularly when push/pull drive element 300 is used in anenergized surgical instrument. However, the exemplary embodimentsdescribed herein are not limited to energized surgical instruments and apush/pull drive element may be used in a non-energized surgicalinstrument. Turning to FIG. 16, a cut-away view of a non-energizedsurgical instrument 400 is shown. Surgical instrument 400 may include ashaft 402, clevis 404, end effector 406, and a push/pull drive element410. End effector 406 may include jaws 420, 430 that may be connected toclevis 404 by a pin 408 inserted through an aperture 405. Push/pulldrive element 410 may be configured according to the exemplaryembodiments of FIGS. 10-15 except that push/pull drive element 410 doesnot include insulative material 308 because surgical instrument 400 isnot energized. As shown in FIG. 17, which shows a cut-away view ofclevis 404, push/pull drive element 410 may include a shaft 412, one ormore engagement portions 414 (such as, for example, engagement portions414 provided by a cross shaft, as discussed above in regard to FIG. 11),and one or more end portions 416. End portion 416 may be inserted withina groove 440 of clevis 404, as discussed above in regard to theexemplary embodiments of FIGS. 10-15, so that end portion 416 is guidedand/or supported when push/pull drive element 410 moves back and forthto actuate end effector 406.

Due to the shape and size of end portions of a push/pull drive elementas described in the exemplary embodiments of FIGS. 10-17, the amount ofcontact area between the end portions and a clevis groove issignificantly increased. Thus, the end portions may advantageouslyenhance the distribution of force exerted between the end portions andgrooves of a clevis. As a result, end portions of a push/pull driveelement may counteract torque and a twisting motion applied to thepush/pull drive element during actuation of an end effector, which mayotherwise lead to deformation or wear of the clevis groove or thepush/pull drive element popping out of the clevis groove. In particular,end portions of a push/pull drive element may minimize or reducepermanent deformation or wear of a groove of a clevis made of anon-metallic material, such as a plastic.

When a surgical instrument is energized, an electrical connection isprovided between an end effector of the surgical instrument and one ormore conduits providing electrical energy to the end effector. However,due to movements of the end effector, providing and maintaining aconnection between the one or more conduits and the end effector may bedifficult. Further, due to the small size of a surgical instrument andthe limited about of space within a surgical instrument, the level ofdifficultly of providing a connection that is functional and durable isrelatively high. For instance, an outer diameter of a surgicalinstrument may be, for example, approximately 5 mm.

Turning to FIG. 18, an exemplary embodiment of a surgical instrument 500is shown that includes jaws 502, 504 connected via a pin 508, a clevis506, and a push/pull drive element 510. Push/pull drive element 510 maybe configured according to the exemplary embodiments of FIGS. 10-17.According to an exemplary embodiment, surgical instrument 500 mayfurther include a connector assembly 530 to connect one or more conduits520, 522 to jaws 502, 504. Conduits 520, 522 may provide energy to jaws502, 504, such as, for example electrical energy, to energize jaws 502,504. FIG. 19 shows surgical instrument 500 with jaw 504 removed so thatcomponents of surgical instrument 500 may be more easily viewed, such asconnector assembly 530. Surgical instrument 500 may further include ashaft (not shown) connected to clevis 506 and covering conduits 520,522.

When jaws 502, 504 are actuated, jaws 502, 504 move relative to othercomponents of surgical instrument 500. For instance, jaws 502, 504 maypivot in direction 540 relative to pin 508, as shown in the exemplaryembodiments of FIGS. 18 and 19. Due to the movement of jaws 502, 504,providing a connection between conduits 520, 522 and jaws 502, 504 canbe challenging. For instance, if conduits 520, 522 are directlyconnected to jaws 502, 504, at least a portion of conduits 520, 522 maymove when jaws 502, 504 move, which may lead to challenges in providinga durable connection between jaws 502, 504 and conduits.

Turning to FIG. 20, an exemplary embodiment of a connector assembly 530is shown, which includes a body 531. Connector assembly 530 may providea connection between one or more conduits 520, 522 and an end effector,such as jaws 502, 504, so that energy (e.g., electrical energy) may beprovided from the one or more conduits 520, 522 to the end effector.Thus, connector assembly 530 may provide an electrical connectionbetween one or more conduits 520, 522 and an end effector, according toan exemplary embodiment. According to an exemplary embodiment, body 531may be made of an insulative material, such as an electricallyinsulative material. For example, body 531 may be made of a plastic,such as, for example, a polyphthalamide (PPA) (e.g., Amadei®, which issold by Solvay Advanced Polymers, L.L.C.). Body 531 may be used, forinstance, to provide a structural support for a connection between oneor more conduits 520, 522 and jaws 502, 504 while substantiallyinsulating components of surgical instrument 500 from the energyconnected between the one or more conduits 520, 522 and jaws 502, 504.As shown in the exemplary embodiment of FIG. 20, body 531 may beapproximately U-shaped and include a first leg 532 and a second leg 534.Further, legs 532, 534 may be separated by a gap 536, as shown in theexemplary embodiment of FIG. 20. Gap 536 may, for example, provide spacefor movement of push/pull drive element 510 within body 531, as shown inthe exemplary embodiment of FIG. 19, such as when push/pull driveelement 510 is moved to actuate jaws 502, 504. Body 531 may furtherinclude a lumen 538 that pin 508 may be inserted through, as shown inthe exemplary embodiment of FIGS. 18 and 19.

According to an exemplary embodiment, legs 532, 534 of body may includea structure to receive conduits 520, 522. For instance, leg 534 mayinclude a cavity 533 to receive conduit 520, as shown in the exemplaryembodiment of FIG. 20. Cavity 533 may be open, as shown in the exemplaryembodiment of FIG. 20, or cavity may be at least partially covered.Conduit 520 may be received in cavity 533 by, for example, insertingconduit 520 through an aperture 535 in leg 534. Leg 532 may beconfigured according to any of the above exemplary embodiments discussedfor leg 534.

As shown in FIG. 21, which is an exploded view of the exemplaryembodiment of connector assembly 530 of FIG. 20, connector assembly 530may further include one or more connector portions 550. According to anexemplary embodiment, connector assembly 530 may include a connectorportion 550 for each conduit. For instance, connector assembly 530 mayinclude a connector portion 550 for each of conduits 520, 522, as shownin FIG. 21. Connector portions 550 may be attached to body 531. As shownin the exemplary embodiment of FIG. 21, connector portions 550 may befit over protuberances 537. Connector portions 550 may have a shapecorresponding to the shape of protuberances 537. Further, connectorportions 550 may be press fit to protuberances 537, according to anexemplary embodiment. According to an exemplary embodiment,protuberances 537 may connect to clevis 506 to attach connector assembly530 and clevis 506.

Connector portions 550 may include one or more structures to attach aconduit. Turning to FIG. 22, which depicts an exemplary embodiment ofconduit 520 attached to connector portion 550, connector portion 550 mayinclude a first attachment 552 to connect connector portion 550 toconduit 520. Connector 550 may further include a second attachment 553,as shown in the exemplary embodiments of FIGS. 21 and 22. For instance,when conduit 520 includes more than one component, such as an outerinsulative cover 523 and a conductor 521, as shown in the exemplaryembodiment of FIG. 22, first attachment 552 may connect to insulativecover 523 while second attachment 553 connects to an exposed portion ofconductor 521. Thus, first attachment 552 may be provided, for example,to assist with maintaining a position of conductor 520 relative toconnector portion 550, while second attachment 553 is provided to forman electrically conductive contact between connector portion 550 andconduit 520, particularly conductor 521. Attachments 552, 553 may beattached to conduit 520 via a mechanical connection, such as, forexample, crimping attachments 552, 553 to conduit 520, via a bond, suchas solder (e.g., soldering attachment 553 to conductor 521), or otherjoining method known to one of ordinary skill in the art. Conduit 522may be connected to connector portion 550 in the same way, according toan exemplary embodiment.

Connector portions 550 may further include one or more structures tocontact a portion of an end effector. For instance, connector portions550 may include a contact portion 554 to contact at least one of jaws502, 504. Contact portion 554 may contact at least one of jaws 502, 504via sliding contact, according to an exemplary embodiment. For instance,as shown in the exemplary embodiment of FIG. 18, jaw 504 may include anaperture 505 so that jaw 504 may be fit over contact portion 554.Further, aperture 505 may be structured to have a shape and sizecorresponding to contact portion 554 so that the portion of jaw 504forming aperture 505 is in contact with contact portion 554. Forinstance, contact portions 554 may have a split ring shape, as shown inthe exemplary embodiments of FIGS. 19, 21, and 22. Thus, when jaw 504moves, such as by pivoting in direction 540 relative to pin 508, jaw 504remains in contact with contact portion 554. Jaw 502 may be configuredaccording to the exemplary embodiments of jaw 504 to also form a slidingcontact with a contact portion 554 of a connector assembly 530. Byconfiguring contact portions 554 of connectors 530 to contact jaws 502,504 via sliding contact, a connection, such as an electrical connection,may be provided between conduits 520, 522 and jaws 502, 504 that isadvantageously durable while permitting movement of jaws 502, 504 andproviding energy to jaws 502, 504 from conduits 502, 504.

According to an exemplary embodiment, connectors 530 may be configuredso that jaws 502, 504 move independently of contact portions 554. Forinstance, when jaws 502, 504 move, such as when jaws 502, 504 areactuated to pivot in direction 540 about pin 508, as shown in theexemplary embodiment of FIGS. 18 and 19, contact portion 554 remainssubstantially stationary as jaw 504 slides over contact portion 554. Asa result, conduits 520, 522 connected to connectors 530 may also remainsubstantially stationary as jaws 502, 504, which may advantageouslyminimize or reduce wear or deformation of conduits 520, 522 andconnections between conduits 520, 522 and connectors 530. Further,conduits 520, 522 are not directly connected to jaws 502, 504 becauseconnectors 530 form connections between conduits 520, 522 and jaws 502,504.

According to an exemplary embodiment, a contact portion 554 may beconnected to the one or more attachment(s) 552, 553 of connectorportions 550 by a bridge 556, as shown in the exemplary embodiment ofFIG. 22. According to an exemplary embodiment, connector portions 550may have a single piece construction. For instance, the one or moreattachment(s) 552, 553, contact portion 554, and bridge 556 may beformed from a single piece, although the exemplary embodiments ofconnector portions 550 described herein are not limited to a singlepiece construction.

According to an exemplary embodiment, connection portions 550 may bemade of a conductive material, such as an electrically conductivematerial, so that energy provided by conduits 520, 522 may be providedto jaws 502, 504 via connector portions 550. For example, connectionportions 550 may be made of a metal, such as, for example, a stainlesssteel.

By providing a surgical instrument with a push/pull drive elementaccording to the exemplary embodiments described herein, a connectionmay be advantageously provided between the push/pull drive element and acomponent of the surgical instrument that has enhanced durability whilepermitting push/pull drive element to move and actuate an end effectorof the surgical instrument. Further, by providing a connector thatpermits sliding contact and/or independent movement between an endeffector and the connector, a connection may be advantageously providedbetween one or more conduits and the end effector that is durable, whilepermitting movement of the end effector and providing energy to the endeffector from the one or more conduit(s).

Further modifications and alternative embodiments will be apparent tothose of ordinary skill in the art in view of the disclosure herein. Forexample, the systems and the methods may include additional componentsor steps that were omitted from the diagrams and description for clarityof operation. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the present teachings. It isto be understood that the various embodiments shown and described hereinare to be taken as exemplary. Elements and materials, and arrangementsof those elements and materials, may be substituted for thoseillustrated and described herein, parts and processes may be reversed,and certain features of the present teachings may be utilizedindependently, all as would be apparent to one skilled in the art afterhaving the benefit of the description herein. Changes may be made in theelements described herein without departing from the spirit and scope ofthe present teachings and following claims.

It is to be understood that the particular examples and embodiments setforth herein are nonlimiting, and modifications to structure,dimensions, materials, and methodologies may be made without departingfrom the scope of the present disclosure and claims, includingequivalents.

Other embodiments in accordance with the present disclosure will beapparent to those skilled in the art from consideration of thespecification and practice of the present disclosure and claims. It isintended that the specification and examples be considered as exemplaryonly, with the claims being entitled to their full scope and breadth,including equivalents.

What is claimed is:
 1. A surgical instrument comprising: a shaft havinga proximal end and a distal end; an end effector coupled to the distalend of the shaft; an electrical transmission conduit extending along theshaft from the proximal end to the distal end and configured to deliverelectrical energy to energize the end effector; and a connector assemblyelectrically coupling the electrical transmission conduit to the endeffector, the end effector being pivotably coupled to the connectorassembly.
 2. The surgical instrument of claim 1 wherein: the endeffector has an aperture, and the connector assembly comprises anelectrically conductive contact portion received in the aperture suchthat the electrically conductive contact portion contacts a portion ofthe end effector surrounding the aperture.
 3. The surgical instrument ofclaim 2 wherein the electrically conductive contact portion defines apivot surface about which the end effector is configured to rotate. 4.The surgical instrument of claim 1 wherein: the end effector is coupledto a clevis positioned at the distal end of the shaft, and the connectorassembly further comprises an electrically insulating member positionedto electrically isolate the end effector and the clevis.
 5. The surgicalinstrument of claim 4 wherein the electrically insulating member of theconnector assembly is coupled with the clevis.
 6. The surgicalinstrument of claim 1 wherein: the end effector comprises an aperture,and wherein the connector assembly comprises a protuberance received inthe aperture.
 7. The surgical instrument of claim 6 wherein theelectrically conductive contact portion comprises a split ringpositioned over the protuberance.
 8. The surgical instrument of claim 1wherein: the electrical transmission conduit comprises a firstelectrical transmission conduit and a second electrical transmissionconduit, wherein the connector assembly comprises a U-shaped body, andwherein each of a first leg and a second leg of the U-shaped bodycomprises a cavity configured to receive a respective one of the firstelectrical transmission conduit and the second electrical transmissionconduit.
 9. The surgical instrument of claim 8 wherein: the surgicalinstrument further comprises a drive element operatively coupled withthe end effector, wherein a portion of the drive element is located in acavity defined between the first and second legs of the U-shaped body.10. The surgical instrument of claim 1 wherein: the end effectorcomprises a clevis, and wherein the connector assembly comprises a boreconfigured to receive a pin, the pin coupling the connector assembly tothe clevis.
 11. The surgical instrument of claim 1 wherein the endeffector comprises first and second jaw members.
 12. The surgicalinstrument of claim 11 wherein: the electrical transmission conduitcomprises a first electrical transmission conduit and a secondelectrical transmission conduit, and wherein the first jaw member iselectrically connected to the first electrical transmission conduit by afirst electrically conductive contact portion of the connector assembly,and the second jaw member is electrically connected to the secondelectrical transmission conduit by a second electrically conductivecontact portion of the connector assembly.
 13. The surgical instrumentof claim 11 wherein: the connector assembly comprises first and secondprotuberances, and wherein the first and second jaw members arepivotably coupled to respective ones of the first and secondprotuberances.
 14. The surgical instrument of claim 11 wherein theconnector assembly comprises an electrically insulating memberpositioned between and electrically insulating at least a portion of thefirst jaw member pivotably coupled to the connector assembly and atleast a portion of the second jaw member pivotably coupled to theconnector assembly.
 15. The surgical instrument of claim 11 wherein thesurgical instrument comprises a drive element operably coupled with andconfigured to actuate the first and second jaw members to move betweenopen and closed positions.
 16. The surgical instrument of claim 1wherein the end effector is configured to deliver electrosurgicalenergy.
 17. A surgical instrument comprising: a connector assemblycomprising a body, a first protuberance extending from the body, and anelectrically conductive first connector including a first contactportion and a first attachment; a first electrical conduit electricallycoupled to the first attachment of the first connector; a firstelectrically conductive jaw including an aperture, the firstprotuberance extending through the aperture of the first jaw, the firstcontact portion surrounding the first protuberance and electricallycontacting the first jaw at the aperture of the first jaw, and the firstjaw pivoting around the first protuberance and the first contactportion; a clevis; and a pin extending through the first protuberanceand securing the first jaw in the clevis.
 18. The surgical instrument ofclaim 17 further comprising: a first actuation aperture defined in thefirst jaw; a first leg and a second leg of the body of the connectorassembly; and a drive element slidably engaged with a first actuationaperture of the first jaw and positioned between the first and secondlegs of the body of the connector assembly.
 19. The surgical instrumentof claim 17 further comprising: a second protuberance extending from thebody of the connector assembly; an electrically conductive secondconnector of the connector assembly including a second contact portionand a second attachment; a second electrical conduit electricallycoupled to the second attachment of the second connector; and a secondelectrically conductive jaw including an aperture, the secondprotuberance extending through the aperture of the second jaw, thesecond contact portion surrounding the second protuberance andelectrically contacting the second jaw at the aperture of the secondjaw, the second jaw pivoting around the second protuberance and thesecond contact portion, and the pin extending through the secondprotruberance and securing the second jaw in the clevis; wherein thebody of the connector assembly is positioned between the first andsecond jaws and is an electrical insulator.
 20. A surgical instrumentcomprising: a pin; an electrically conductive connector including acontact portion and an attachment, the contact portion surrounding thepin; an electrical conduit electrically coupled to the attachment of theconnector; and an electrically conductive jaw including an aperture, thecontact portion electrically contacting the jaw at the aperture of thejaw, and the jaw being pivotable around the contact portion.